Asphalt shingle, roof covering therewith and method of making the same with synchronized adhesive positioning thereon

ABSTRACT

A method of making the asphalt shingles includes applying a substrate to a layer of shingle-forming material, the substrate having indicators at predetermined spaced-apart distances, with the indicators being sensed as the shingle-forming layer is moved along a predetermined path, with adhesive zones being applied to the shingle such that the application of the adhesive zones is synchronized in response to sensing the locations of the indicators, and with the shingle-forming layer then being cut into individual shingles.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a division of pending U.S. application Ser. No. 13/155,736,filed Jun. 8, 2011, which is a continuation-in-part of U.S. applicationSer. No. 12/560,724 filed Sep. 16, 2009, the complete disclosures ofeach of which are herein incorporated by reference.

BACKGROUND OF THE INVENTION

Asphalt shingles have been manufactured for many years by impregnating aweb of mat, generally of fiberglass material, with a bitumen, such asasphalt, and applying granules of desired color and/or contrast to thatsurface of the shingle that would be the upper surface of the shinglewhen the shingle is in an installed condition on a roof. Generally, theshingle is constructed to have multiple tabs separated by slots cutinward of the shingle from the lower edges of the tabs, to leave thetabs spaced-apart relative to each other. Sometimes the granules in theheadlap or butt portion of the shingle; i.e., above the tabs, are of adarker, less expensive nature, because generally the headlap portion ofthe shingle will be covered when shingles are laid up on a roof incourses, with shingles in a next-overlying course covering headlapportions of shingles in a next underlying course, and with eachoverlying course of shingles being staggered longitudinally (leftward orrightward) relative to the next underlying course of shingles.

It is also known in the shingle/roofing art that it is the tab portionsof shingles that are weather-exposed in the installed condition, andthereby it is the tabs of shingles that can be lifted up by windconditions, and that if such tabs are bent upwardly a sufficient amount,they can crack and, if the wind conditions are severe enough, can beblown off the roof.

Accordingly, it is known to provide wind resistance for tabs of shinglesthat are installed on a roof. Such resistance is usually effected byapplication of adhesive beneath the tab portions of shingles, generallyat the lower ends of the tabs, so that the lower ends of the tabs areadhesively secured to headlap portions of shingles in a next-underlyingcourse of field shingles of a roof covering.

SUMMARY OF THE INVENTION

The present invention is directed to providing an asphalt shingle havinga base mat impregnated with an asphalt material and having a headlapportion and a tab portion, with the tab portion comprising a pluralityof tabs separated by slots, and with adhesive applied on the top surfaceof the shingle in the headlap portion above the upper ends of the slots,but wherein the headlap portion of the shingle has adhesive-free zonesabove the centers of the tabs.

The invention also includes a roof covering of shingles as describedimmediately above, wherein the shingles of overlying courses are offsetlongitudinally (leftwardly or rightwardly) relative to shingles in anext-underlying course, and wherein the adhesive-free zones in headlapportions of shingles are uncovered by shingles in a next-overlyingcourse, such that no adhesive of a shingle of an underlying course isvisible through slots of shingles in a next-overlying course.

This invention is also directed to a method of making an asphalt shinglethat includes applying a substrate layer to a layer of shingle-formingmaterial, wherein the substrate layer has indicators at predeterminedspaced-apart distances, wherein those indicators are sensed as theshingle-forming layer is moved along a predetermined path and then theplacement of adhesive zones onto the headlap portion of the uppersurface of the shingle forming layer is synchronized in response to thesensing of the locations of the indicators, and wherein theshingle-forming layer is cut into individual shingles.

Accordingly it is an object of this invention to provide a single layerasphalt shingle as described above, or a multi-layer shingle with slotsthat go all the way through the multiple layers.

It is another object of this invention to provide a roof covering asdescribed above.

It is a further object of this invention to provide a method of makingan asphalt shingle as described above.

It is a further object of this invention to synchronize the slot cuttingstep of making the shingle in response to the sensing of the indicatorson the substrate layer.

It is another object of this invention that the synchronizing stepincludes changing the relative placement of the adhesive zones inresponse to the sensing step.

BRIEF DESCRIPTIONS OF THE DRAWING FIGURES

FIG. 1 is plan view of a shingle in accordance with this invention,showing zones of adhesive present in the headlap portion of the shingle,generally above the slots that separate tabs, and wherein adhesive-freezones are shown in phantom in the headlap portion of the shingle, abovethe centers of the tabs.

FIG. 2 illustrates an array of two shingles as they would appear if laidup on a roof in courses, with each shingle in a next-overlying course ofshingles being longitudinally (leftwardly or rightwardly) offsetrelative to a shingle in a next-underlying course, such that theadhesive-free zones of shingles in a next-underlying course appearthrough the slots of shingles in a next-overlying course, such that theadhesive zones of shingles in an underlying course are covered by tabsof shingles in a next-overlying course, and wherein no adhesive inheadlap portions of shingles in an underlying course is visible throughthe slots between tabs of shingles in a next-overlying course.

FIG. 3 is an illustration of a partial roof covering of shingles of thetype of FIGS. 1 and 2.

FIG. 4 is a schematic illustration of various steps in the method ofmaking a shingle in accordance with this invention, wherein the relativeplacement of the adhesive zones and the slots is effected by changingthe delivery of the shingle-forming layer to the adhesive applicator andthe slot cutter.

FIG. 5 is an illustration like that of FIG. 4, but wherein the relativeplacement of the adhesive zones and the slots is effected by changingthe position of the adhesive applicator and slot cutter.

DETAILED DESCRIPTIONS OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in detail, reference is first made to FIG.1, wherein the shingle 10 of this invention is illustrated in plan viewas being comprised of a single layer of shingle material made of anasphalt impregnated mat with granules applied to its top surface 11. Itwill be understood that the shingle could alternatively be one ofmulti-layer construction with slots that go through the multiple layers.The shingle 10 has a headlap portion 12 and a tab portion 13.

In the embodiment shown, the tab portion 13 is a four-tab shingle havingtabs 14, 15, 16 and 17 separated by slots 18 that extend from the loweredge 20 of the shingle, at the lower ends of the tabs, up to the headlapportion 12 of the shingle. It will be understood that the shingle couldalternatively be a two tab, a three-tab or a shingle with five or moretabs.

It will be understood that the tabs 14-17 may contain decorativegranules of different colors and/or contrasts, as may be desired, andthat the headlap portion 12 may have dark granules thereon, as shown, orany other type of granules.

It will also be understood that particulate material, such as sand,mica, or other material may be applied to the underside (not shown) ofthe shingle 10, as desired.

Adhesive stripes 21, 22 and 23 are shown in the headlap portion 12 ofthe shingle 10, above the upper ends of the slots 18. In the embodimentshown, the stripes 21-23 are shown in two vertically spaced-apart bands,with a pair of stripes 21, 22 placed at the lower end of the headlapportion 12 of the shingle 10, above the slots 18, but just to the leftand right of the slots 18, and that the band of stripes 23 is placedsomewhat above the lower band of stripes 21, 22, above the upper ends ofthe slots 18, with the left and right ends of the stripes 23, leavingadhesive-free zones 24 of a width “D” at the lower end of the headlapportion 12 of the shingle 10, between the stripes 21, 22 and betweenadjacent stripes 23, just above the center lines 25 (shown in phantom),midway between left and right edges 26, 27 of each of the tabs 14-17.These adhesive-free zones 24 are shown in the form of imaginary lines,as are the center lines 25, in order to depict the portions of theheadlap portion 12 of the shingle 10 that will not have adhesive appliedthereto during the manufacturing process. It will thus be understoodthat the adhesive-free zones 24 as well as the center lines 25 would notappear to be visible as phantom lines as shown in FIG. 1, but that thesame are shown in phantom in FIG. 1, for illustrative purposes only.

Between the adhesive stripes 21 and 22, there is a space that is free ofadhesive, directly above each slot 18. This space is particularlyadapted to be a fastening zone, for placement of a fastener, such as anail, for fastening the shingle 10 to a roof, either manually, or by useof a nailing gun, stapling gun or the like.

With reference now to FIG. 2, it will be seen that a shingle 10, inaccordance with this invention is presented as a shingle in anunderlying course of shingles, and that other shingles in that samecourse would be arranged end-to-end. A shingle 10′ is shown asrepresenting a shingle in a next-overlying course of shingles, and itwill likewise be understood that a plurality of shingles 10′ would belaid up in the next-overlying course, end-to-end.

Also, in FIG. 2, it will be seen that the tabs 14′-17′ of the shingle10′ are disposed laterally (longitudinally) offset leftward and/orrightward, such that the imaginary center lines 25′ are aligned abovethe slots 18 that separate tabs 14-17 of shingle 10.

In this manner, the tabs 14′-17′ of shingles 10′ in an overlying courseof shingles will cover the adhesive zones 21-23 of shingles in thenext-underlying course, leaving no adhesive zones visible through theslots 18′ between adjacent tabs 14′-17′ of shingles 10′.

Also, with reference to FIGS. 1 and 2, it will be seen that theadhesive-free zones 24 on the top surface of the headlap portions of theshingles are of at least a length L corresponding to the length of theslots between tabs, and are at least of a width W corresponding to thewidth of the slots between the tabs, to slightly into the headlapregion.

In FIG. 3, a building 30 is illustrated, having a roof 31 having a roofcovering 32 of shingles in accordance with this invention. In FIG. 3, aplurality of courses 33-39 is illustrated, with alternate courses havingtheir shingles 10 staggered longitudinally (leftwardly or rightwardly)relative to shingles in a next-underlying course, such that slots 18 ofshingles 10 in a next-overlying course are centered above tabs ofshingles in a next-underlying course and such that adhesive zones 21-23in headlap portions of shingles in underlying courses are covered bytabs of shingles in next-overlying courses, leaving no adhesive visiblethrough slots that separate tabs of overlying courses.

With reference now to FIG. 4, it will be seen that a web 45 of base matis provided, moving along a predetermined path in the direction of thearrow 46, with the web 45 being delivered to a bath 47 of bitumenmaterial, preferably asphalt, in a vessel 48, whereby a roller 50 picksup asphalt and applies it to the mat 45, to be absorbed throughout themat 45 by being engaged between the lower roller 50 and an upper roller51, such that asphalt is applied throughout the mat 45, and to its uppersurface 52, as well as its lower surface 53.

The thus impregnated mat 45 is then delivered past a granule applicator54, having a plurality of granule applicator bins 55, 56, 57, 58 and 60for applying granules to an upper surface 52 of the impregnated mat 45by dropping them onto the upper surface 52, in the direction of thearrows 61, such that the granules thus applied will adhere to the uppersurface 52 of the impregnated mat 45.

Granules of preferably smaller particulate material in the form of sand,mica or the like may be applied to the undersurface 53, if desired, byany of several conventional means known in the art.

It will be understood that, in the manufacture of a shingle-forminglayer 45 in accordance with this invention, the layer may bemanufactured in the form of a pair of side-by-side shingle-forming layerportions simultaneously, in accordance with that portion of thedisclosure of parallel shingle-forming layers as manufactured accordingto U.S. Pat. No. 6,212,843, the complete disclosure of which is hereinincorporated by reference.

As the shingle-forming layer moves along its predetermined path as shownin FIG. 4, a roll of substrate 59 is unrolled, as shown, and applied inthe direction of the arrow 62 shown in FIG. 4, to meet with theundersurface 53 of the shingle-forming layer 45, prior to the passage ofthe substrate layer 59 and shingle-forming layer 45 around the roller63, and then around the roller 65 as shown. The substrate 59 hasadhesive on its surface 64, and is applied to the undersurface 53 of theshingle-forming layer 45, such that it will adhere thereto, and that,after the substrate 59 and shingle-forming layer 45 come together aroundroller 63, they continue as a unit as shown around the roller 65.

A sensor 66, aimed at the undersurface 53 of the shingle-forming layer45, senses predetermined, spaced-apart indicators (not shown) on theundersurface of the shingle-forming layer 45 as the shingle-forminglayer 45 passes thereover, as shown at 67, and transmits thatinformation via transmission line 68, to a controller 70. The controller70 may be a programmable logic computer (PLC).

The substrate layer that is provided from roll 59 may be in the form ofa tape that provides an indication in the form of a physical mark, amagnetic device, an infrared device, a hole, a photocell, that may beread by the sensor 66. The sensor 66 may take on various forms, such asa lightness or darkness detector, a metal or magnetic detection device,a barcode reader, an infrared detection device, a hole detection device,a photocell, a CCD array image reader or any other form of detectiondevice, many of which are well known in the art and which can detectsome difference caused by a mark or indicator of various types passingthereby.

The connection 68 between the sensor 66 and the controller 70 can be inthe form of a wired connection, a signal line, or a wirelesstransmission line providing a signal from the sensor 66 to thecontroller 70, microprocessor, or computer of any type.

The controller 70, in response to detection information received fromthe sensor 66 sensing information from an indicator, delivers thatinformation via control line 71 to a drive mechanism 72 for a take-upmechanism 73. The drive mechanism 72 can adjust the take-up rollermechanism 73 upwardly or downwardly as shown by the double headed arrow74 to adjust the delivery of shingle-forming layer 45, to increase ordecrease the delivery of the shingle-forming layer after it passesaround roller 75, and prior to its passing around roller 76, in order tosynchronize the delivery of shingle-forming layer 45 to adhesiveapplicators 77 of adhesive applicator roller 78 as it rotates in thedirection shown by the arrow 79, to pick up adhesive 80 from adhesivevessel 81 and apply it to the surface 52 of the shingle-forming layer45, as that surface comes into contact with the adhesive applicators 77.

Adhesive is thus applied in the form of stripes 82 prior to theshingle-forming layer passing around the roller 83.

It will be understood that the adhesive that is applied via theapplicators 77, while being described as being in the form of stripes,could be in the form of squares, circles, or any other geometric shapeas may be desired, and as will function in accordance with thisinvention, all of which are embraced within the term “adhesive zones” or“adhesive”.

After application of the adhesive 82, and as the shingle-forming layer45 then passes around the roller 83, a doctor blade 84 may contact theadhesive 82, to even out the thickness of adhesive zones.

After passing around the roller 83, the shingle-forming layer continuesin its movement along a predetermined path, to pass around roller 85.The controller 70, via control line 86 may control a drive mechanism 87,to move the same upwardly or downwardly as shown by the double headedarrow 88, so that the drive mechanism may adjust the position of atake-up roller mechanism 90, in response to a signal received via thetransmission line 68 from the sensor 66, in order to adjust theplacement of the shingle-forming layer 45 relative to a slot-cuttingroller 91, after delivery of the shingle-forming layer 45 around roller92.

The slot-cutting roller 91, rotating in the direction of the arrow 93,as shown, may be provided with one or more cutting blades 94, forcutting the slots between adjacent tabs in the shingle-forming layer.

Thus, the take-up mechanisms 72, 73; 87, 90 may be used to synchronizethe placement of adhesive zones on a surface of the shingle-forminglayer in response to the sensing of the locations of the indicators, andmay additionally adjust the placement of the slots such that they aresynchronized in response to the sensor 66 sensing the locations of theindicators. In this regard, the synchronizing step includes changing therelative placement of any of the adhesive zones and the slots inresponse to sensing the locations of the indicators. This changing ofthe relative placement of the adhesive zones with or without the sensingof the relative placement of the slots can be effected by changing thedelivery of the shingle-forming layer to the adhesive applicator, and,if desired, to the slot cutter as shown in FIG. 4.

Thereafter, the shingle-forming layer 45 may be delivered to any ofvarious mechanisms known in the art, such as a looper, a cooler (notshown), and eventually to a cutting roller 95 rotating in the directionof the arrow 96, as shown, with the cutting roller 95 having at leastone cutting blade 97 thereon, for cutting individual shingles to desiredlengths.

With reference now to FIG. 5, an alternative arrangement isschematically illustrated for changing the relative placement of theadhesive zones, and, if desired, also changing the relative placement ofthe slots in response to the sensing of indicators. In the arrangementillustrated in FIG. 5, to the extent that components are in common withthe arrangement of FIG. 4, the same numerals will be used, and, to theextent that there are differences between the embodiments of FIGS. 4 and5 different numerals will be used, as shown and described.

In the embodiment illustrated in the schematic of FIG. 5, the controller70, via control line 100 can control the movement of the drive mechanism101, back or forth as shown by the double headed arrow 102, to effect achange in position of the adhesive applicator 81 relative to theshingle-forming layer 45, as an alternative way of synchronizing theplacement of adhesive zones 82 on the shingle-forming layer, by drivingthe adhesive applicator 81 via drive line 103, as shown. Similarly, thecontroller 70, via control line 105, can control the movement of theslot cutter 94 through the drive mechanism 106, via drive line 107, formovement of the slot cutter 94 backward or forward as shown by thedouble-headed arrow 107, for synchronizing the cutting of slots in theshingle-forming layer 45, as an alternative way of changing the relativeplacement of the slots in response to the sensing of indicators on theshingle-forming layer via the sensor 66.

It will be apparent from the foregoing that various modifications may bemade in the details of construction of the shingles, as well as in themethods of manufacture of the shingles of this invention, all within thespirit and scope of the invention as defined in the appended claims.

What is claimed is:
 1. A method of making an asphalt shingle in amanufacturing environment in which the shingle has a headlap region anda tab region, with granules applied to an upper surface of the shinglethat is to be weather-exposed in the installed condition on a roof, themethod comprising: (a) providing a shingle-forming layer comprised ofshingle reinforcement material impregnated with a bitumen material, thelayer having a butt region and a tab region, and including the step ofdelivering the layer along a predetermined path; (b) providing a layerof granules on an upper surface of the shingle-forming layer; (c)applying a substrate layer with a plurality of indicators carriedthereby to the shingle-forming layer, with the indicators being providedat predetermined spaced-apart distances from each other; (d) sensing thelocations of the indicators; (e) then actuating the placement ofadhesive zones onto the upper surface of headlap portions of theshingle-forming layer and synchronizing the placement of the adhesivezones on the upper surface of the shingle-forming layer in response tothe sensing step of clause (d); and (f) cutting the shingle-forminglayer into individual shingles, wherein the tab region of the shinglecomprises a plurality of tabs defined by slots formed through the entirethickness of the shingle and extending from a lower edge of the tabregion to the headlap region, each tab having a centerline, each slothaving a length L and a width W, and wherein the adhesive zones areplaced leaving adhesive-free zones on the upper surface of the headlapregion registered with the centerlines of the tabs, such that noadhesive is disposed in registration with the centerlines, eachadhesive-free zone having a length of at least L and a width of at leastW.
 2. The method of claim 1, including the step of cutting slots in thetab region of the shingle-forming layer to separate the tab region intoa plurality of spaced-apart tabs.
 3. The method of claim 2, wherein theslot cutting step includes synchronizing the placement of the slots inthe shingle-forming layer in response to the sensing step of clause (d)of claim
 1. 4. The method of claim 1, wherein the synchronizing stepincludes changing the relative placement of any of: (a) the adhesivezones; and (b) the slots in response to the sensing step of clause (d)of claim
 1. 5. The method of claim 4, wherein the placement of adhesivezones is done with an adhesive applicator and wherein the placement ofslots is done with a slot cutter, and wherein the step of changing therelative placement includes effecting a change in the delivering of theshingle-forming layer to any of: (a) the adhesive applicator; and (b)the slot cutter.
 6. The method of claim 4, wherein the step of changingthe relative placement includes effecting a change in position of anyof: (a) the adhesive applicator; and (b) the slot cutter relative to thedelivering of the shingle-forming layer.
 7. The method of claim 2,wherein the synchronizing step includes changing the relative placementof any of: (a) the adhesive zones; and (b) the slots in response to thesensing step of clause (d) of claim
 1. 8. The method of claim 7, whereinthe placement of adhesive zones is done with an adhesive applicator andwherein the placement of slots is done with a slot cutter, and whereinthe step of changing the relative placement includes effecting a changein the delivering of the shingle-forming layer to any of: (a) theadhesive applicator; and (b) the slot cutter.
 9. The method of claim 7,wherein the step of changing the relative placement includes effecting achange in position of any of: (a) the adhesive applicator; and (b) theslot cutter relative to the delivering of the shingle-forming layer. 10.The method of claim 3, wherein the synchronizing step includes changingthe relative placement of any of: (a) the adhesive zones; and (b) theslots in response to the sensing step of clause (d) of claim
 1. 11. Themethod of claim 10, wherein the placement of adhesive zones is done withan adhesive applicator and wherein the placement of slots is done with aslot cutter, and wherein the step of changing the relative placementincludes effecting a change in the delivering of the shingle-forminglayer to any of: (a) the adhesive applicator; and (b) the slot cutter.12. The method of claim 10, wherein the step of changing the relativeplacement includes effecting a change in position of any of: (a) theadhesive applicator; and (b) the slot cutter relative to the deliveringof the shingle-forming layer.
 13. The method of claim 1, wherein theindicators comprise physical marks on the substrate.
 14. The method ofclaim 13, wherein the physical marks comprise holes in the substrate.15. The method of claim 1, wherein the indicators are sensed by amagnetic detection device, an infrared device, a barcode reader, a metaldetection device, a hole detection device, a CCD image reader, or aphotocell.
 16. The method of claim 1, wherein the substrate comprises atape bearing indicators.
 17. The method of claim 16, further comprisingproviding the substrate from a roll.